Device for forming post sleeves, and method of use

Abstract

A post sleeve installation assembly includes: an elastomeric sleeve core shaped to form a post sleeve when positioned in uncured concrete, a removable stiffener inside the core, an aperture extending lengthwise in the stiffener, a locking element positioned within the core, and an assembly plate coupled to the stiffener. The assembly plate clamps to a prefabricated sleeve element, with the core and stiffener positioned within a post cavity of the sleeve element. an installation stake is positioned in the aperture and prevented from sliding upwards by the locking element. A release point on the assembly plate permits an operator to release the locking element for removal of the stake. To install a post sleeve, the operator positions the installation assembly, clamped to a prefabricated sleeve element, in a post hole with the stake resting on the bottom, then fills the hole with concrete, manipulating the stake to position the assembly.

The invention claimed is: 
     
       1. A post sleeve installation system to assist in forming a post sleeve within a post hole in the ground to include a post sleeve cavity to insertably receive and support a post, the post sleeve installation system comprising:
 a post sleeve core configured to be removed from a hardenable material that is deposited in the ground and used to form the post sleeve about the post sleeve core, the post sleeve core having an upper end and a lower end and having an exterior surface sized and shaped to define at least a portion of the post sleeve cavity of the post sleeve when the post sleeve core is removed from the hardenable material; 
 an elongate installation member removably coupleable to the post sleeve core and translationally adjustable relative to the post sleeve core to protrude a selected distance beyond a lower end of the post sleeve core to assist in positioning the post sleeve core at an elevated height within the post hole during formation of the post sleeve; 
 a locking mechanism coupled to the lower end of the post sleeve core and operable upon the elongate installation member, the locking mechanism resisting translation of the elongate installation member when in a locked state and enabling translation of the elongate installation member when in an unlocked state; and 
 an actuatable release device coupled to the upper end of the post sleeve core which is operable by a user, the actuatable release device moving the locking mechanism from the locked state to the unlocked state and allowing translational movement of the elongate installation member in an upward direction relative to the post sleeve core upon actuation of the release device by the user. 
 
     
     
       2. The post sleeve installation system of  claim 1  wherein the post sleeve core comprises:
 an elastomeric sheath that defines the exterior surface of the post sleeve core and includes a stiffener cavity, the elastomeric sheath inwardly deformable to assist in removal of the elastomeric sheath from the hardenable material used to form the post sleeve about the post sleeve core; and 
 a core stiffener removably insertable in the stiffener cavity of the elastomeric sheath to temporarily reinforce the elastomeric sheath while the hardenable material used to form the post sleeve is positioned around the elastomeric sheath and hardens to form the post sleeve. 
 
     
     
       3. The post sleeve installation system of  claim 1 , wherein the locking mechanism resists translation of the elongate installation member relative to the post sleeve core in at least an upward direction while the elongate installation member supports a weight of the post sleeve core as the post sleeve is formed about the post sleeve core. 
     
     
       4. The post sleeve installation system of  claim 3  wherein the locking mechanism includes opposing cam members configured to resist translation of the elongate installation member relative to the post sleeve core in at least the upward direction while the elongate installation member supports the weight of the post sleeve core as the post sleeve is formed about the post sleeve core. 
     
     
       5. The post sleeve installation system of  claim 1 , further comprising:
 a clamping mechanism coupled to the upper end of the post sleeve core and being configured to releasably engage a prefabricated post sleeve component selected to be deposited in the post hole and to suspend the prefabricated post sleeve component within the post hole such that the hardenable material and the prefabricated post sleeve component collectively form the post sleeve as the hardenable material hardens. 
 
     
     
       6. A post sleeve installation system to assist in forming a post sleeve within a post hole in the ground to include a post sleeve cavity to insertably receive and support a post, the post sleeve installation system comprising:
 a post sleeve core configured to be removed from a hardenable material that is deposited in the ground and used to form the post sleeve about the post sleeve core, the post sleeve core having an upper end and a lower end and having an exterior surface sized and shaped to define at least a portion of the post sleeve cavity of the post sleeve when the post sleeve core is removed from the hardenable material; 
 a locking mechanism coupled to the lower end of the post sleeve core and movable between a locked state and an unlocked state, the locking mechanism configured to resist translation of an elongate installation member insertable in the post sleeve core when in the locked state and to enable translation of the elongate installation member when in the unlocked state to enable the post sleeve core to be selectively repositioned along a length of the elongate installation member; and 
 an actuatable release device coupled to the upper end of the post sleeve core which is operable by a user, the actuatable release device moving the locking mechanism from the locked state to the unlocked state and allowing translational movement of the elongate installation member in an upward direction relative to the post sleeve core upon actuation of the release device by the user. 
 
     
     
       7. The post sleeve installation system of  claim 6  wherein an upper portion of the exterior surface of the post sleeve core is shaped to be received within an interior cavity of a prefabricated post sleeve cap, and wherein the post sleeve core is elongated to protrude beyond the prefabricated post sleeve cap when coupled thereto. 
     
     
       8. The post sleeve installation system of  claim 6  wherein the post sleeve core comprises:
 an elastomeric sheath that defines the exterior surface of the post sleeve core and includes a stiffener cavity, the elastomeric sheath inwardly deformable to assist in removal of the elastomeric sheath from the hardenable material used to form the post sleeve about the post sleeve core; and 
 a core stiffener removably insertable in the stiffener cavity of the elastomeric sheath to temporarily reinforce the elastomeric sheath while the hardenable material used to form the post sleeve is positioned around the elastomeric sheath and hardens to form the post sleeve. 
 
     
     
       9. The post sleeve installation system of  claim 6 , further comprising:
 the elongate installation member, the elongate installation member being removably coupleable to the post sleeve core and translationally adjustable relative to the post sleeve core to protrude a selected distance beyond a lower end of the post sleeve core to assist in positioning the post sleeve core at an elevated height within the post hole during formation of the post sleeve. 
 
     
     
       10. The post sleeve installation system of  claim 9  wherein the locking mechanism includes opposing cam members configured to resist translation of the elongate installation member relative to the post sleeve core in at least an upward direction while the elongate installation member supports a weight of the post sleeve core as the post sleeve is formed about the post sleeve core. 
     
     
       11. The post sleeve installation system of  claim 6 , further comprising:
 a clamping mechanism coupled to the upper end of the post sleeve core and being configured to releasably engage a prefabricated post sleeve component selected to be deposited in the post hole and to suspend the prefabricated post sleeve component within the post hole such that the hardenable material and the prefabricated post sleeve component collectively form the post sleeve as the hardenable material hardens. 
 
     
     
       12. A post sleeve installation system to assist in forming a post sleeve within a post hole in the ground to include a post sleeve cavity to insertably receive and support a post, the post sleeve installation system comprising:
 a post sleeve core configured to be removed from a hardenable material used to form the post sleeve about the post sleeve core, the post sleeve core having an upper end and a lower end and having an exterior surface sized and shaped to define at least a portion of the post sleeve cavity of the post sleeve when the post sleeve core is removed from the hardenable material; 
 a locking mechanism coupled to the lower end of the post sleeve core and movable between a locked state and an unlocked state, the locking mechanism configured to resist translation of an elongate installation member insertable in the post sleeve core when in the locked state and to enable translation of the elongate installation member when in the unlocked state; 
 an actuatable release device coupled to the upper end of the post sleeve core which is operable by a user, the actuatable release device being configured to move the locking mechanism from the locked state to the unlocked state and allow movement of the elongate installation member upon actuation of the release device by the user; and 
 a clamping mechanism coupled to the upper end of the post sleeve core and being configured to releasably engage a prefabricated post sleeve component selected to be deposited in the post hole and to suspend the prefabricated post sleeve component within the post hole such that the hardenable material and the prefabricated post sleeve component collectively form the post sleeve as the hardenable material hardens.